Roof attachment assembly for solar panels and installation method

ABSTRACT

Disclosed herein is a roof attachment assembly for mounting a solar panel on a roof without the use of rails. The assembly includes a flashing member, a pivot bracket member, a clamp member, an array skirt and a splice member. The flashing member anchors the roof attachment assembly to the roof. The pivot bracket member is rotatably connected to the flashing member. The clamp member is connected to the pivot bracket member and is rotatably connected thereto. The clamp member includes grounding elements for electrically grounding the solar panel. The array skirt is removably connected to the clamp member. The splice member includes grounding elements for electrically grounding the solar panel and is removably connected to the array skirt. Also disclosed is a method of using the assembly and an assembly kit.

FIELD OF THE DISCLOSURE

The present invention relates generally to roof attachment assembly forsolar panels and a method of installation of such solar panels on aroof. More particularly, this disclosure relates to components that forma roof attachment assembly, to provide efficient and easy installationof solar panels on a roof using rail-less guides.

BACKGROUND

In the past, it has been recognized that mounting and installing solarpanels on a roof without rail guides is advantageous. Installing railguides, under certain conditions, can be problematic. In fact, undersome conditions, installation can be quite lengthy and expensive.

Consequently, a rail-less mounting system for solar panels has beendeveloped in response to this need. Rail less mounting systems providethe ability to mount the solar panels in a flexible manner. In fact, therail less mounting system allows this flexibility and enables the panelsto be located virtually anywhere on the roof. This, in turn, allowsinstallers of the solar panels to provide more flexible solutions tosolar panel installations. And in certain difficult installationconfigurations, this will allow the installation of panels where theymight not otherwise have been able to be installed.

In response to this need, US patent application publication 2011/0000519and U.S. Pat. No. 8,756,881 disclose a rail-less mounting system forsolar panels. But each of these disclosures has undesired limitations.For example, the element that connects the solar panel to the roof inpublication '519 above, as shown in FIGS. 25, 29, 30 and 31, is affixedto the roof and thereby limits and inhibits the installation of thesolar panels.

In order to introduce flexibility into the installation process,publication '519 relies upon a two-piece clamping mechanism. As can beappreciated by those skilled in the art of installation of solar panels,the less parts that are needed to install the foundational elements tosupport the solar panels, and the more flexible the elements are interms of movement and location, the easier the installation processbecomes.

Additionally, certain past and present systems have not properlyaccounted for the storage or concealment of wire bundles that areprevalent when installing solar panels. A failure to properly concealthe wire bundles can cause the solar panel array to be aestheticallyunpleasant.

What is needed is a simplified apparatus and method for installing solarpanel modules on a roof without the necessity of having rail guides. Forexample, allowing the solar panel to be installed on a fully rotatableclamp and mount is advantageous and has not been disclosed by any priorreference. Additionally, eliminating multi-piece structures such as theclamp in publication '519 represents a significant improvement in theart.

SUMMARY OF THE DISCLOSURE

This disclosure is summarized below only for purposes of introducingembodiments of the disclosure. The ultimate scope of the disclosure isto be limited only to the claims that follow the specification.

This disclosure provides a roof attachment assembly for mounting solarpanels on a roof using a rail-less mounting system.

It is an object of the present invention to provide a roof attachmentassembly that includes a pivoting mount for connecting to a flashingassembly that in turn is secured to a roof;

It is a further object of the present invention for the pivoting mountto be rotatable 360 degrees with respect to the flashing assembly;

It is a further object of the present invention for the pivoting mountto move in a back-and-forth motion along an opening where the mount issecured to a flashing assembly;

It is a further object of the present invention to provide a clampingmember for securing items such as solar panel modules or array skirts toinstall a solar panel array on a roof;

It is a further object of the present invention for the clamping memberto be rotatably coupled to the pivoting mount;

It is a further object of the present invention for the height of theclamping member to be adjustable by rotating the clamping member in aclockwise or counterclockwise direction;

It is a further object of the present invention to provide a securelocking mechanism for coupling the array skirts and solar panel modulesto the clamping member;

It is a further object of the present invention to provide a groundingfeature in the clamping member;

It is a further object of the present invention to provide a conduit onthe clamping member for storing electrical wiring used to install thesolar panel array; and

It is a further object of the present invention to provide a method forassembling the various elements as described in the description of theinvention below.

BRIEF DESCRIPTION OF THE DRAWINGS

A more complete understanding of the present invention may be derived byreferring to the detailed description and claims when considered inconnection with the following illustrative figures. In the followingfigures, like reference numbers refer to similar elements and stepsthroughout the figures.

FIG. 1 is an exploded view of a portion of the roof attachment assembly,illustrating a flashing member, a pivot bracket member, and a clampingmember.

FIG. 2 illustrates, in exploded view, the flashing member beingconnected to the array skirt and a solar panel.

FIG. 3 illustrates, in prospective view, a first row of solar panelsattached to a roof using the roof attachment assembly of thisdisclosure.

FIG. 4 is a cross-sectional view of one exemplary embodiment of the roofattachment assembly in accordance with this disclosure.

FIG. 5 is a prospective you of the splice member in accordance with thisdisclosure.

FIG. 6 is a side view of the splice member attached to a solar panel.

FIG. 7 is a side view of the array skirt being connected to the roofattachment assembly.

FIG. 8 illustrates the array skirt falling mounted to the roofattachment assembly.

FIG. 9 illustrates, in prospective view, a solar panel connected to theclamping member of the roof attachment assembly.

FIG. 10 illustrates, in prospective view the splice member connectingtwo array skirts attached thereto.

DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENTS

In the following description, and for the purposes of explanation,numerous specific details are provided to thoroughly understand thevarious aspects of the invention. It will be understood, however, bythose skilled in the relevant arts, that the present invention may bepracticed without these specific details. In other instances, knownstructures and devices are shown or discussed more generally in order toavoid obscuring the invention. In many cases, a description of theoperation is sufficient to enable one to implement the various forms ofthe invention, particularly when the operation is to be implemented insoftware. It should be noted that there are many different andalternative configurations, devices and technologies to which thedisclosed embodiments may be applied. The full scope of the inventionsis not limited to the examples that are described below.

With particular reference to FIG. 1, a first exemplary embodiment of theroof attachment assembly is shown generally designated by the numeral20. The roof attachment assembly includes a flashing member 22. Theflashing member 22 includes a hanger bolt 24 having self-tapping threadsfor engagement into the roof (not shown) as is well known in theindustry. The flashing member 22 includes a taper lock compression seal29 around the hanger bolt 24 to prevent leakage. In another exemplaryembodiment, the hanger bolt 24 has custom threads which facilitates itsconnection to various custom devices.

The roof attachment assembly 20 includes a pivot bracket member 26. Thepivot bracket member 26 has a first opening 28 adapted for compatiblefit with the hanger bolt 24. The opening 28 is generally oval orrectangular in shape. Hardware is provided, which includes the taperlock compression seal 29 to secure the hanger bolt 24 to the pivotbracket member 26, while allowing the pivot bracket member 26 to rotate360 degrees relative to the flashing member 22. The hanger bolt 24 issecured to the pivot bracket member 26 with a hanger nut 25. When thehanger nut 25 is secured to the hanger bolt 24, it still allows for full360-degree rotation of the pivot bracket member 26 as well as allowingthe pivot bracket member 26 to slide along the first opening 28 in aback and forth motion. A cover 27 fits on top of the opening 28 once thepivot bracket member 26 is secured to the flashing member 22.

The pivot bracket member 26 has a second opening 32. A leveling bolt 34extends through and is anchored at the second opening 32. Hardware isprovided to anchor the leveling bolt 34 at opening 32 as shown. Thepivot bracket member 26 includes a level indicator 37, which is moreclearly seen in FIGS. 6 and 7, illustrates the ability of the installerto view the level of the solar panel upon installation.

The roof attachment assembly 20 includes a clamping member 40. Theclamping member 40 has a first and a second side, 50 and 52,respectively. A base 57 joins the sides 50 and 52 and forms an opening55 between the sides. Each of the sides 50 and 52 includes a top and abottom arm, 54 and 56, respectively. The clamping member 40 includesgrounding pins 42 on the bottom arm 56. In the embodiment shown in FIG.1, the arm 56 includes one grounding pin 42. In other exemplaryembodiments more than one grounding pin 42 is contemplated and it isfurther contemplated that the grounding pin 42 appears on the upper arm54 or on both arms 54 and 56.

The grounding pins 42 are placed where contact is expected by itemstrapped within the clamping member 40. This assures secure electricalcontact and a robust ground.

The clamping member 40 further includes structure for managing wire usedin the solar panel installation. The wire can, and often does, appear inbundles or harnesses. The clamping member 40 includes a wire bundleconduit 45. In order to preserve the electrical integrity of the solarpanel installation, the wires of this disclosure are properly placed andcare is given to preserve the electrical integrity.

In another exemplary embodiment, the clamping member 40 is made from aspring-like material. Each of the arms 54 and 56 are normally urgedtoward one another. Thus, any item trapped by the arms 54 and 56 isgripped securely between these arms. Ideally, the arms 54 and 56 of theclamping member 40 exert such a force that the grounding pins 42penetrate the anodized surface of the solar panel module. This creates asecure grounding system. This is a similar type of grounding systemdisclosed earlier in application Ser. No. 13/542,570 and U.S. Pat. No.9,142,700, which are specifically incorporated herein by reference.

With particular reference to FIG. 2, there is shown a plurality of arrayskirts 60 connected to the flashing member 22 on a roof. A solar panel100 is shown being connected to the adjacent array skirt 60. As shown inFIGS. 4, 7, 8 and 10 the clamping member 40 traps the array skirt 60within its arms 54 and 56. A splice 80, best shown in FIGS. 5 and 10,secures the end of one solar panel module 100 to the end of the otheranother solar panel module 100. Between each splice member 80, aclamping member 40 retains and secures the array skirt 60.

With particular reference to FIG. 3, there is shown a plurality of solarmodules 100. Each of the solar panel modules 100 is connected to thearray skirt 60 and the clamping members 40 and splice member 80 asdescribed above. FIG. 3 shows the first row of solar panel modules 100connected. As can be seen from FIG. 3, other rows can likewise beconnected without the need of additional array skirts 60. It will alsobe appreciated that no rails or guide rails are necessary for thisinstallation when using the roof attachment assembly 20 and the splice80.

With particular reference to FIG. 4, there is shown, in cross-section,the roof attachment assembly 20 connected to a roof using the flashingmember 22. The pivot bracket member 26 is shown connected to the roofthrough the flashing member 22 using the hanger bolt 24. The taper lockcompression seal 29 prevents moisture from leaking onto the roof throughthe pivot bracket member 26.

Also as shown, the leveling bolt 34 is threaded through the secondopening 32 of the pivot bracket member 26. As noted above, the clampingmember 40 rotates 360° relative to the roof along the leveling bolt 34.Therefore, the height of the array skirt 60 and the solar panel 100 canbe easily adjusted to the desired height for the particular applicationby rotating the clamping member 40. The level indicator 37 allows theinstaller to view the amount of adjustment made.

Also as illustrated in FIG. 4, the array skirt 60 and the solar panelmodule 100 are fully connected to the roof attachment assembly 20. Withparticular reference to FIGS. 7 and 8, the method of installation of thearray skirt 60 with the roof attachment assembly 20 is illustrated.

With particular reference to FIG. 5, there is shown the splice member80. The splice member 80 is typically installed between two array skirts60 and two solar panels 100 as shown in FIG. 10. The splice member 80attaches each of the array skirts 60 and solar panels 100 to one anotheras best shown in FIGS. 3 and 10. The splice member 80 has a constructionsimilar to the clamping member 40. The splice member 80 has a first side82 and a second side 84. A bridge 86 connects the sides 82 and 84. Eachof the sides 82 and 84 include a pair of arms 88 and 90. In an exemplaryembodiment, the splice member 80 is made from a spring like materialwith the arms 88 and 90, being normally urged toward one another. Thus,any item that is trapped within the arms is secured by the spring likematerial. As defined herein, the term “item” means either a solar panel100 or an array skirt 60.

As illustrated, the splice member 80 includes a grounding pin 92. In theembodiment illustrated, the grounding pin 92 is located on the bottomarm 90. In other exemplary embodiments, the grounding pin 92 is locatedon the upper arm 88. In other exemplary embodiments, the grounding pin92 is located on one arm 90 of the splice member 80. Within the spiritand scope of the invention, it is contemplated that multiple groundingpins 92 are used in various locations where electrical grounding contactis desired. The splice member 80 also includes a separator 114. Theseparator 114 serves to keep the solar panels apart so that theyfunction properly. Separator 114 insures separation between eachsuccessive solar panel 100 installed on the splice member 40.

FIG. 6 illustrates another exemplary embodiment of the clamping member40. In this embodiment, the clamping member 40 includes grounding pins42 as shown. The clamping member 40 further includes a level indicator37. Additionally, the upper arm 54 of the clamping member 40 is providedwith a gripping member 61 which serves to enhance the gripping functionof the clamping member 40. As shown in FIG. 6, the clamping member 40includes a wire bundle conduit 45.

With particular reference to FIGS. 7 and 8, there is shown the operationof installing the array skirt 60 into the clamping member 40. Initially,the array skirt 60 is rotated and slid into the arms of the clampingmember 40. As the rotation continues, the array skirt 60 is snapped inplace. As shown in the exemplary embodiment of FIGS. 7 and 8, theclamping member 40 includes a reverse notch 69 for securing the arrayskirt 60 into place. It will also be appreciated that array skirt 60includes a compatible notch 63. Together, these compatible matingnotches 69 and 63 worked together to create a secure snap lock for thearray skirt 60 to the clamping member 40.

With particular reference to FIG. 9, there is shown a perspective viewof the assembled clamping member 40 connected to solar panel 100. Asseen, the gripping member 61 along with the action of the arms 54 and 56grips the solar panels 100 securely in place. The grounding pin 42 cutsthrough the exterior surface of the solar panel and creates thegrounding contact desired.

In order to rotate and make fine adjustments to the correct height ofthe solar panel 100, a socket drive 110, which acts as an adjustmentnut, is provided. Also, see FIG. 1. The socket drive 110 is rotated toallow vertical movement of the solar panel 100 upon rotation.

With particular reference to FIG. 10, the splice member 80 is shownconnecting a first and a second solar panel 100 on one side of thesplice member 80 using the method described herein. On the other side ofthe splice member 80, the splice member 80 is shown ready forinstallation of a pair of solar panels 100. As shown, a separator 114 isprovided in accordance with the objects described above.

The Method of Installation

An exemplary embodiment of the method of installation using the roofattachment assembly 20 described herein is described below. Initially,the flashing member 22 is mounted on the roof using the hanger bolt 24.Once the flashing member 22 is secured to the roof, the pivot bracketmember 26 is secured to the flashing member 22 using hanger bolt 24 andthe hanger nut 26. The leveling bolt 34 is then threaded through secondopening of pivot bracket member 26 and secured thereto. The clampingmember 50 is rotatably attached to the leveling bolt 34. As describedearlier the leveling bolt 34 is used to adjust the height of theclamping member. The height adjustment is seen in the level indicator37. This allows accurate adjustment of the height of the solar panelmodule 100.

What is claimed is:
 1. A rail-less roof attachment assembly for mountinga solar panel on a roof having a flashing member, comprising: a. aclamping member comprising: i. a first and a second side positioned onopposite sides of the clamping member and an opening positioned betweenthe first and second sides; ii. a grounding element embedded in each ofthe first and second sides;
 1. the first and second sides respectivelyfurther comprising a top and a bottom arm forming an opening forreceiving an item wherein at least one of the bottom arms furthercomprises a reverse notch; b. a pivot bracket member comprising: i. afirst side for rotatably coupling the pivot bracket member to theflashing assembly; ii. a second side for rotatably coupling the pivotbracket member to the clamping member.
 2. The rail-less roof attachmentassembly as set forth in claim 1, wherein the grounding element ispositioned on the bottom arm of at least one of the first and secondsides of the clamping member and defines a grounding pin for makingsecure electrical connection.
 3. The rail-less roof attachment assemblyas set forth in claim 1, wherein the assembly further comprises aleveling bolt, the leveling bolt located in the opening, positionedbetween the first and second sides of the clamping member, forconnecting the pivot bracket member to the clamping member and whereinthe leveling bolt facilitates adjustment of the height of the clampingmember relative to the pivot member.
 4. The rail-less roof attachmentassembly as set forth in claim 3, wherein the leveling bolt is threadedand further comprises a socket drive on one end of the leveling bolt andwherein the rotation of the socket drive adjusts the height of theclamping member relative to the pivot bracket member.
 5. The rail-lessroof attachment assembly as set forth in claim 1, wherein the clampingmember—further comprises a level indicator located in the openingpositioned between the first and second sides of the clamping member. 6.The rail-less roof attachment assembly as set forth in claim 1, whereinat least one of the first and second bottom arms further comprises awire harness conduit.
 7. The rail-less roof attachment assembly as setforth in claim 1, wherein the clamping member is made from a spring-likematerial and wherein the arms are normally urged toward one another. 8.The rail-less roof attachment assembly as set forth in claim 1, whereinthe clamping member rotates 360° relative to the pivot bracket member.9. The rail-less roof attachment assembly as set forth in claim 1,wherein the pivot bracket member rotates 360° relative to the roof. 10.The rail-less roof attachment assembly as set forth in claim 1, whereinthe assembly includes an array skirt member.
 11. The rail-less roofattachment assembly as set forth in claim 10, wherein the array skirtmember comprises a compatible mating notch to the reverse notch.